Stable and efficient building system

ABSTRACT

A plurality of different types of modules are used to form external and internal walls of a building system. Adjacent modules are interlocked by first and second fitting surfaces of respective adjacent modules. First and second adjacent modules are attached using a fastening system which includes a fixing rod and wall fitting unit. A fitting surface of the first adjacent module is fitted with the wall fitting unit and the fixing rod is inserted through the second adjacent module.

FIELD OF THE INVENTION

The present invention relates generally to building construction. Moreparticularly, the present invention relates to building modules forcreating building structure.

BACKGROUND OF THE INVENTION

In the construction of buildings, cinder blocks are commonly used.Typically, building construction begins with forming the foundation ofthe building and frame, with appropriate supports, such as columns andbeams. After the frame is completed, blocks are stacked and joined toform external walls, with windows and doorways as desired.

Mortar is used to join the blocks together. The joining of blocks toform external walls required skilled labor, which increases productioncosts. Additionally, blocks are heavy, creating shipping and handlingissues.

From the foregoing discussion, it is desirable to provide an efficientand stable building system.

SUMMARY OF THE INVENTION

The present invention relates to building construction. In one aspect ofthe invention, it relates to a building system. The building systemcomprises a plurality of different types of modules for forming externaland internal walls of a building structure. Adjacent modules areinterlocked by first and second fitting surfaces of respective adjacentmodules. The building system further comprises a fastening system forattaching first and second adjacent modules. The fastening systemcomprises a fixing rod and wall fitting unit. One of the fittingsurfaces of the first adjacent module is fitted with the wall fittingunit and the fixing rod is inserted through the second adjacent module.

In another aspect of the invention, a method of assembling a buildingsystem is disclosed. The method comprises providing a building structurebase. Corner modules are mounted to the building structure base atcorners of the building structure base. The method further comprisesmating interconnecting types of building modules sequentially from thecorner modules, wherein adjacent interconnecting types of buildingmodules are mated by male and female fitting surfaces. Adjacentinterconnecting types of building modules are attached with a fasteningsystem. The fastening system comprises a wall fitting unit mounted onthe fitting surfaces of one of the modules and inserting a fixing rodthrough the other of the adjacent module and mating with the wallfitting unit.

In yet another aspect of the invention, a method of forming a module ofa building system is provided. The method includes preparing ageopolymer mixture of the module. The geopolymer mixture is insertedinto an extrusion system. The method further comprises the step ofextruding a module from a mold, wherein the module comprises at least afirst fitting surface for mating with a module with a second fittingsurface. The first fitting surface comprises one of a male or femalesurface and the second fitting surface comprises other of a male orfemale surface.

These and other objects, along with advantages and features of thepresent invention herein disclosed, will become apparent throughreference to the following description and the accompanying drawings.Furthermore, it is to be understood that the features of the variousembodiments described herein are not mutually exclusive and can exist invarious combinations and permutations.

BRIEF DESCRIPTION OF THE DRAWINGS

In the drawings, like reference characters generally refer to the sameparts throughout the different views. Also, the drawings are notnecessarily to scale, emphasis instead generally being placed uponillustrating the principles of the invention. In the followingdescription, various embodiments of the present invention are describedwith reference to the following drawings, in which:

FIGS. 1 a-b show side and plan views of a generic module in accordancewith one embodiment of the invention;

FIGS. 2 a-b show female and male fitting surfaces in accordance with oneembodiment of the invention;

FIGS. 2 c-e show various detailed views of a module in accordance withone embodiment of the invention;

FIGS. 3 a-j show various types of modules of a building system inaccordance with one embodiment of the invention;

FIG. 4 illustrates a plan view of a module assembly in accordance withone embodiment of the invention;

FIGS. 5 a-b show different views of mating modules in accordance withone embodiment of the invention;

FIGS. 6 a-c show fastening system for securing adjacent modules inaccordance with one embodiment of the invention;

FIG. 7 shows a corner module mated with middle modules in accordancewith one embodiment of the invention;

FIGS. 8 a-b show a plan view and a detailed view of a building structurein accordance with one embodiment of the invention;

FIGS. 9 a-b show an attachment unit for corner modules in accordancewith one embodiment of the invention;

FIGS. 9 c-d show base bolts in accordance with different embodiments ofthe invention; invention;

FIGS. 10 a-b show an attachment unit for middle modules in accordancewith one embodiment of the invention;

FIGS. 11 a-b show a final attachment unit in accordance with oneembodiment of the invention;

FIGS. 12 a-b show an assembled final middle module in accordance withone embodiment of the invention;

FIGS. 13 a-b show a pillar module in accordance with one embodiment ofthe invention;

FIGS. 14 a-d show a column assembly in accordance with one embodiment ofthe invention;

FIGS. 15 a-c show a window assembly in accordance with one embodiment ofthe invention;

FIGS. 16 a-b show a door frame in accordance with one embodiment of theinvention;

FIGS. 17 a-b show a door frame assembly in accordance with oneembodiment of the invention;

FIGS. 18-19 show a plumbing outlet in accordance with one embodiment ofthe invention;

FIGS. 20 and 21 show a garage door assembly in accordance in accordancewith one embodiment of the invention;

FIGS. 22 a-b and 23 a-b show a roof plate assembly in accordance withone embodiment of the invention;

FIGS. 24 a-c show a roof plate assembly in accordance with anotherembodiment of the invention;

FIG. 25 shows a process for assembling a building structure inaccordance with one embodiment of the invention; and

FIG. 26 shows a process for fabricating building modules in accordancewith one embodiment of the invention.

DETAILED DESCRIPTION OF THE INVENTION

The present invention relates to a building system. In accordance withone embodiment of the invention, the building system comprises aplurality of building modules. The modules, for example, serve assegments which can be easily interconnected or assembled to form abuilding structure. In one embodiment, the modules are used to formwalls (internal and external) and serve as support or load bearingstructures. Various types of modules are provided to effect the desiredbuilding or floor plan. For example, the modules can be used to formsingle or multi-story building structures with the desired layout (e.g.,shape, number and size of rooms).

In accordance with the invention, the modules are easily attached usingfasteners, such as bolts and wall fittings with nuts. The modules can beeasily adapted for use with conventional building structures. Forexample, the modules can be used with conventional bases and supports aswell as roofing structures.

FIGS. 1 a-b show side and plan views of a generic module 100 inaccordance with one embodiment of the invention. As shown, the modulecomprises an elongated member comprising generally a rectangularcross-section with four sides or surfaces 102-105. Providing moduleswith other geometric shaped cross-sections is also useful. The elongatedmember comprises a length L, width W and thickness T. W and T, forexample, are equal to the length and thickness of a conventional cinderblock. For example, W is about 0.30-0.41 m and T is about 0.2 m. Thelength, in one embodiment, is equal the height of a typical wall of thebuilding structure. For example, L is about 2.7 m. Preferably, themembers are provided in two different lengths, such as 2.6 and 2.7 m.The different lengths correspond to the different heights for externaland internal walls. For example, the longer length modules are used toform external walls while the shorter length modules are for internalwalls. The modules can also be cut to the desired length, for example,to accommodate door or window frames or different height ceilings.Providing modules with other values of T, W, and L are also useful.

In one embodiment, at least one of the sides of the module comprises asmooth or flat surface. The flat surface serves as, for example, eitherone of the surfaces of a building wall structure, such as inner, outeror end. Some modules can have two, three or all flat surfaces. Thenon-flat surfaces serve as fitting surfaces. A fitting surface can be amale or female fitting surface. For modules with more than one fittingsurfaces, they can be male, female or a combination thereof. In the casewhere a module comprises four flat surfaces, no fitting surfaces areprovided.

Preferably, the module comprises at least one cavity 108 that extendsthe length of the module. As shown, the module comprises two cavitiesthat extend the length of the module. Providing cavities that extendpartially may also be useful. The cavities can serve various functions.For example, the cavities can provide insulation or space forinsulation, accommodate for utility or services, such as electricalwiring or plumbing as well as reducing weight of the modules. In oneembodiment, the number of cavities depends on the width of the module.The modules can have various unit widths, with each unit having onecavity. For example, in the case of modules having full and half widths,full width comprises two cavities while half width comprises one cavity.Other configurations of units and cavities are also useful.

FIG. 2 a shows female and male fitting surfaces 212 and 222 inaccordance with one embodiment of the invention. The female and malefitting surfaces interlock adjacent modules. In one embodiment, thefemale fitting surface comprises one or more receptacles 213 forreceiving one or more protrusions 223 from the male fitting surface.When mated, in one embodiment, the male and female fitting surfaces oftwo adjacent modules create an opening or cavity 218 therebetween, asshown in FIG. 2 b. The opening provides space to accommodate fastenersfor fixing adjacent modules together.

Referring back to FIG. 2 a, a plane formed by the female fittingsurface, as indicated by the dotted line A-A, comprises recesses 213 and216. Preferably, the recesses extend the length of the module.Illustratively, the female fitting surface comprises three recesses, oneeach located at the edges of the surface and one in the middle. Otherarrangements are also useful. The plane formed by the male fittingsurface, as indicated by the dotted line B-B, comprises first and secondprotrusions 223 corresponding to the mating recesses of the femalesurface. The protrusions include a notch or a step 224 for mating withthe recesses of the female surface. Furthermore, the male fittingsurface comprises a 226 recess between the protrusions. The recesses 216and 226 facilitate in creating the opening between two mated surfaces toaccommodate, for example, fasteners. Other arrangements of the matingsurfaces are also useful.

FIG. 2 c shows details of a module 200 in accordance with one embodimentof the invention. As shown, the module comprises a full width modulehaving first and second cavities 208 that extend its length. The moduleincludes smooth surfaces 202 and 204 along the width W which serves aswalls. Along the thickness T of the module are female and male fittingsurfaces 212 and 222. Measurements of various components of the moduleare provided. All measurements are in millimeters (mm).

FIGS. 2 d-e show 3-dimensional and fitting surface views in detail of amodule 200 in accordance with one embodiment of the invention. Themodule comprises, for example, a length L of 2.6 m with first and secondfitting surfaces 212 and 222. A fitting surface (212 or 222) includes atop set of holes 265 and a bottom set of holes 266. As shown, a set ofholes include four holes. Providing other number of holes per set or topand bottom sets with different numbers of holes is also useful. Formodules having two opposing fitting surfaces, holes are through holes,from one fitting surface to the other. In one embodiment, the top andbottom set of holes facilitate assembly to an adjacent module. Forexample, the holes can be fitted with a wall fitting unit or for a boltto pass through. The holes, in one embodiment, are about 12 mm indiameter. Other hole sizes are also useful, depending on the fastenersize or design.

In one embodiment, the set of holes are provided 100 mm from the top orbottom surface, with succeeding holes at 100 mm intervals. For thelonger size modules of 2.7 mm, the bottom set of holes are provided 200mm from the bottom surface at 100 mm intervals. Additionally, a fittingsurface includes hole markings 268 located between the sets of holes.The hole markings provide locations for holes to be formed duringassembly process if needed. The hole markings, in one embodiment, arespaced apart by 200 mm from holes or other hole markings. Otherarrangements or configurations for placement of holes or hole markingsare also useful. In one embodiment of the invention, the bottom of thefitting surface includes recess or routing 227. The recess serves toaccommodate, for example, brackets to fix a module to the base of thebuilding structure. The recess, for example, is about 10 mm deep. Otherrecess depths are also useful.

In one embodiment, the modules comprise a geopolymer composite. Oneexample of the composition of the polymer composite is listed inTable 1. Other types of materials are also useful. For example, themodules can be formed of wood or cement.

TABLE 1 Material ≈ % Cement Portland Type 1 29 Fly Ash 30 CalciumCarbonate 10 Recycled Paper Fiber 3 Chemical Methyl Cellulose 1 Water 19Recycled Dust (e.g., dust recycled from sanding 8 modules)

The composite is preferably formed by extrusion. Other processes, suchas casting, are also useful. The technical data of the composite modulesare listed in Table 2.

TABLE 2 Module Properties ≈ Compressive strength 20-45 MPa Bendingstrength 7-15 MPa Modulus of elasticity 10-20 MPa Specific density1.3-2.1 kg/dm³ Fire rating integration 2-4 hours Thermal resistance <1W/° C./m² Moisture absorption <8% Sound deduction 40 db

The use of geopolymer composite produces modules which are lightweightand strong. For example, a panel having a size of 100 mm×300 mm×2600 mmweighs only about 39 kg. Additionally, the geopolymer composite modulesare fire retardant and resistant to moisture.

FIGS. 3 a-j show plan views of various types of building modules inaccordance with one embodiment of the invention. The modules areconfigured with first and second sizes. For example, the modules areeither full or half size. Providing modules with more or less number ofsizes are also useful.

Referring to FIG. 3 a, a corner module 330 a is shown. The corner moduleis used to create corners or bends in the building structure. In oneembodiment, the corner module comprises a rectangular shape having firstand second adjacent flat surfaces 305 a-b and first and second adjacentfitting surfaces 312 and 322. The flat surfaces, as shown, areperpendicular or form a 90° angle. Likewise the fitting surfaces areperpendicular. The fitting surfaces are configured to mate with othermodules to create perpendicular walls. In one embodiment, the firstsurface comprises a female fitting surface and the second fittingsurface comprises a male fitting surface. The corner module comprises ahalf size module with one cavity 318. The female fitting surface ismated to a male fitting surface of a first adjacent module; the malefitting surface is mated to a female fitting surface of a secondadjacent module. Other configurations, such as shape and size of themodule or number, angle, or type of fitting surfaces as well as numberof flat surfaces are also useful. For example, more than two fittingsurfaces can be provided to create an intersection having more than twowalls.

Referring to FIG. 3 b, a T-connection module 330 b is shown. TheT-connection module is used to join a wall with another in the buildingstructure. In one embodiment, the T-connection module comprises a halfsize rectangular shaped module with one cavity 318, first, second andthird fitting surfaces 322, 312 a and 312 b and a flat surface 305. Thefirst and second fitting surfaces are located on opposing sides of themodule while the third fitting surface is perpendicular to the otherfitting surfaces. In one embodiment, one of the first and secondsurfaces comprises a female fitting surface and the other comprises amale fitting surface. As illustrated, the first surface comprises a malefitting surface and the second comprises a female fitting surface. Thethird fitting surface comprises a female fitting surface, forming afemale-type T-connection module. When mated to fitting surfaces of othermodules, a T-shaped wall structure is formed. As such, the walls arejoined at a 90° angle. T-connection modules having other configurations,such as shape and size of the module or number, angle, or type offitting surfaces as well as number of flat surfaces are also useful.

Referring to FIG. 3 c, a T-connection module 330 c in accordance withanother embodiment is shown. The T-connection module comprises a fullsize rectangular shaped module with two cavities 318 a-b, first, secondand third fitting surfaces 322 a, 312 and 322 b and a flat surface 305.The first and second fitting surfaces are located on opposing sides ofthe module while the third fitting surface is perpendicular to the otherfitting surfaces. Since the module is a full size module, the thirdfitting surface comprises fitting and smooth 306 surfaces, with thefitting surface located at one side of the module. Providing the fittingsurface in the middle of the module is also useful. In one embodiment,one of the first and second surfaces comprises a female fitting surfaceand the other comprises a male fitting surface. As illustrated, thefirst surface comprises a male fitting surface and the second comprisesa female fitting surface. The third fitting surface comprises a malefitting surface, forming a male-type T-connection module. When mated tofitting surfaces of other modules, a T-shaped wall structure is formed.As such, the walls are joined at a 90° angle. Other configurations, suchas shape and size of the module or number, angle, or type of fittingsurfaces as well as number of flat surfaces are also useful. For examplethe third fitting surfaces can include more than one fitting surfacesformed at an angle other than 90°.

An end module 330 d in accordance with one embodiment is shown in FIG. 3d. The end module comprises a half size rectangular shaped module with acavity 318. In one embodiment, the end module comprises a fittingsurface 312 on one side while the remaining sides 305 a-c are flatsurfaces. The end module serves to form the end of a wall. The fittingsurface, as shown, comprises a female fitting surface. Providing a malefitting surface 322 as shown in FIG. 3 f, is also useful. Alternatively,as shown in FIGS. 3 e and 3 g, end modules can be full size end moduleswith two cavities 318 a-b with either a male fitting surface 322 orfemale fitting surface 312. Other configurations, such as angle of thefitting surfaces to form bends at the end of the wall is also useful.

FIG. 3 h shows a middle module 330 h in accordance with one embodimentof the invention. The middle module comprises a half size rectangularshaped module with a cavity 318. Providing a full size module 330 ihaving two cavities 318 a-b, as shown in FIG. 3 i, or other sizes isalso useful. In one embodiment, the middle module comprises first andsecond fitting surfaces 312 and 322 on opposing sides while theremaining sides 305 a-b are flat surfaces. The middle module is used toconnect other modules on the fitting surfaces to form, for example,middle section of the wall. In one embodiment, the first fitting surfacecomprises a female fitting surface and the second fitting surfacecomprises a male fitting surface. Other configurations, such as shapeand size of the module or type of fitting surfaces are also useful. Forexample, the flat surfaces can include an angle to create bends in thewall or the fitting surfaces can be of the same type.

A pillar module 330 j in accordance with one embodiment is shown in FIG.3 j. The pillar module comprises a full size rectangular shaped modulewith two cavities 318 a-b. Providing pillar modules of other sizes isalso useful. In one embodiment, the pillar end module comprises flatsurfaces 305 a-d. Other configurations, such as shape and size of themodule, are also useful. For example, the flat surfaces can include anangle.

FIG. 4 illustrates a plan view of a module assembly 400 of variousmodules in accordance with one embodiment of the invention. In oneembodiment, a corner module 430 a is provided. Various modules can bemated together along a first direction X with the corner module to forma first wall 450 of the module assembly. In one embodiment, the fittingsurface of the corner module in the first direction comprises a femalemating surface. For example a middle module 430 i, male-typeT-connection module 430 c and full size male-type end module 430 g aremated sequentially to the corner module in the X direction to form afirst wall 450 of the module assembly. Various modules can be matedtogether along a second direction Y with the male-type T-connectionmodule. As shown, middle module 430 i and female-type half size endmodule 430 d are sequentially mated to the male-type T-connection module430 c to form a second wall 452 of the module assembly. Othercombinations of modules can also be used to form the first and secondwalls, as desired.

A third wall 454 is formed by various modules sequentially mated to thecorner module in the Y direction. In one embodiment, the mating surfaceof the corner module in the Y direction comprises a male fittingsurface. As shown, a full size middle module 430 i, half size middlemodule 430 h, half size female-type T-connection module 430 b, twomiddle modules 430 i and a full size female-type end module 430 e aresequentially connected to the corner module in the Y direction. A fourthwall 456 is formed along the X direction by mating various modules tothe half size female-type T-connection module 430 b. For example, amiddle module 430 i and a half size male end module 430 f aresequentially mated to the female-type T-connection module 430 b.Illustratively, the second and fourth walls do not merge. Merging thesecond and fourth wall by, for example, a corner module can form anenclosed room 440.

In accordance with one embodiment of the invention, structural supportof the building structure is provided by column modules. As shown, afull size column module 430 j is mated to one of the middle modules 430i ₁ on the third wall. Column modules can be mated to the walls or asstand alone columns as needed, depending on for example designrequirements.

FIGS. 5 a-b show different views of securing modules in accordance withone embodiment of the invention. As shown, first and second modules 530₁ and 530 ₂ are provided. The male fitting surface 522 ₁ of the firstmodule is mated to the female fitting surface 512 ₂ of the secondmodule. In one embodiment, the modules have top holes 565 and bottomholes 566 on the fitting surfaces. For middle modules, the holes arealso provided in the internal surface 514 which separates the cavities.In one embodiment, 4 top holes and 4 bottom holes are provided for themodules. Providing other number of holes is also useful. Preferably, thetop and bottom holes are located on the fitting surface such that thetop and bottom of the module can be interchangeable.

A fastening system is used to secure the two modules together. In oneembodiment, the fastening system comprises a fixing rod 570 and a wallfitting unit 571. A fastening system can be used for the top and bottomportion. For example, a wall fitting unit is fitted into one of the topand bottom holes on the female fitting surface of the second module. Tosecure the modules, fixing rods are inserted through one of the top andbottom holes of the female fitting surface 512 ₁ of the first module andscrewed into the wall fitting unit. Other configurations, such asmounting the wall fitting unit to a male fitting surface of one moduleand inserting the fixing rod through the male fitting surface of anotherare also useful.

FIG. 6 a shows a fastening system in accordance with one embodiment ofthe invention. FIGS. 6 b-c show a wall fitting unit in greater detail inaccordance with one embodiment of the invention. Referring to FIG. 6 a,the fastening system comprises a fixing rod 570 and a wall fitting unit571. Male thread is provided on the fixing rod which is mated to femalethread on the wall fitting unit. The size of the fastening system issufficient to secure the modules. For example, the fixing rod is formedfrom galvanized steel having a diameter of 8 mm with M6 thread on oneend and a hex head and shoulder on the other while the wall fitting unitincludes M6 internal thread and an outer diameter of 11.5 mm. Othermaterials or dimensions are also useful.

Referring to FIGS. 6 b-c, the wall fitting unit in one embodimentcomprises head, body and end portions 674-676. The head portioncomprises an opening for the fixing rod to pass through and the endportion comprises female thread which mates with the male thread of thefixing rod. The body portion comprises fingers 679. The body portioncomprises a length L greater than the thickness of the fitting surface.Preferably, the threaded portion is about the thickness of the fittingsurface for fitting thereto while the finger portion extends beyond thefitting surface. As the fixing rod is mated to the wall fitting unit andtightened, the threaded end portion moves towards the head, as indicatedby the arrow. When the end portion moves towards the head portion, itexpands the fingers of the body portion. This causes the wall fittingunit to be securely locked into the fitting surface. Preferably thefitting unit is permanently locked into the fitting surface. The use ofthe fastening system of the present invention enables easy removal ofmodules for expansion or renovation by merely removing the fixing rods.

FIG. 7 shows securing of modules in accordance with one embodiment ofthe invention. As shown, a corner module 730 ₁ includes female and malefitting surfaces 712 ₁ and 722 ₁. Wall fitting units 771 are insertedinto top and bottom holes on the fitting surfaces. Male fitting surface722 ₂ of, for example, a first middle module 730 ₂ is mated to thefemale fitting surface of the corner module; female fitting surface 712₃ of, for example, a second middle module 730 ₃ is mated to the malefitting surface of the corner module. To secure the middle modules tothe corner modules, fixing rods 770 are inserted through the modules andmated with the wall fitting units. In one embodiment, fastening systemsare provided at the top and bottom parts of the modules. Otherconfigurations of fastening systems are also useful. Additionally middlemodules as well as other modules can be connected therefrom to formwalls in the X and Y directions to create the desired layout.

FIG. 8 a shows a plan view of a building structure in accordance withone embodiment of the invention. A base 890 is provided on which modulesare assembled. The base, for example, comprises a slab of concretehaving the shape of the perimeter of the building structure. The basecan be formed by conventional techniques. Modules 830 are fixed to theperimeter of the base, as indicated by the dotted lines, forming theinternal space of the building structure. Other types of materials orshapes are also useful. For example, the slab can be designed to extendbeyond the outer walls of the building structure. In a preferredembodiment, as shown in FIG. 8 b, the base comprises a step 891. Modulesrest on a base 891 a of the step while a back 891 b of the step providesadditional vertical support and serving as a barrier from externalelements. The longer modules (e.g., 2.7 m) serve as outer walls of thebuilding structure which rest on the step and the shorter modules (e.g.,2.6 m) serve as interior walls. For example, the width of the step isequal to about the width W of the module while the height can be about100 mm. A sealant can be applied to the modules in the step portion toprevent penetration of water or other environmental elements.

The modules can easily be adapted to use for multi-level buildingstructures, including basements. For example, conventional foundationand building support structures can be used to providing the frameworkto which the modules are installed.

FIGS. 9 a-b show an attachment unit in accordance with one embodiment ofthe invention. The attachment unit is used to mount or fix a module tothe base. In one embodiment, the attachment unit comprises a supportbracket 844. The support bracket, for example, comprises an L-shapedbracket with a back and foot portions 847 a-b. The bracket, for example,comprises galvanized steel of about 5 mm thick. Other materials orthicknesses are also useful. The back portion is attached to a fittingsurface of the module while the foot is fixed to the base. A pluralityof openings 848 a-b are provided on the foot and back portions tofacilitate attaching the support bracket to the module and base. In oneembodiment, the back comprises four vertical slotted openingcorresponding to the four holes on the bottom of the fitting surface anda circular opening on the foot portion. The slotted openings allow forleveling adjustments to be made due to, for example, variations in thebase. Providing the back and foot portions with other number or types ofopenings is also useful.

First wall fittings 870 ₁ for attaching the support bracket areinstalled into holes in the fitting surface. In one embodiment, wallfittings are inserted into first and last holes of the set of pluralityof holes in the lower portion of the module. For example, the first andfourth holes of the set of plurality of holes are fitted with wallfittings. A second wall fitting 870 ₂ is also fitted into one of theholes between the first and last holes of the set of plurality of holes,for example, either the second or third hole. The second wall fitting ismated with a fixing rod for securing an adjacent module. First bolts 873are mated to the first wall fittings through the first and fourthvertical slotted openings to attach the support bracket to the fittingsurface of the module.

A second bolt 881 is inserted through the first opening in the supportbracket for attaching the module to the base. In one embodiment, thesecond bolt comprises a base bolt. The base bolt, for example, anchorsthe module to the base. The second bolt, for example, comprises aDynabolt™ system manufactured by Ramset. FIG. 9 c shows a Dynabolt™system 881 a. The Dynabolt™ can be installed by inserting it into a hole885 drilled into the base 890. As a bolt 889 is tightened, fingers 886expand to anchor the Dynabolt™ in place. Alternatively, the second boltcomprises a ChemSet™ system 881 b manufactured by Ramset as shown inFIG. 9 d. The ChemSet™ can be installed by drilling a hole 885 into thebase 890. The hole is filled with the ChemSet™ adhesive 887 andinserting a bolt 888 into the hole. As the adhesive sets, the bolt ispermanently fixed to the base, anchoring the module thereto. The secondbolt can be formed from galvanized steel with an outside diameter of 10mm. Other techniques for anchoring the module are also useful.

For a corner module 830, an attachment unit is provided at the bottom ofeach fitting surface, for example, female and male fitting surfaces 812and 822. Attachment units can also be provided for the middle modules,shown in FIG. 10 a to provide additional structural stability. Theattachment unit can be mounted onto a fitting surface 822 of a middlemodule 830 ₁ after being attached to an adjacent module 830 ₂. In oneembodiment, the attachment unit is provided for every third to sixthmiddle module. Providing other arrangement of attachment units formiddle modules is also useful and may depend on design requirements. Forexample, attachment units can be provided for every one, every othermiddle module, or other number of middle module is also useful. Asshown, the attachment unit is mounted onto a male fitting surface.Mounting the attachment unit to a female fitting surface, for exampledepending on the configuration, is also useful. To accommodate the footof the support bracket, a recess 827 is provided at the bottom of thefitting surface, as shown in FIG. 10 b. The recess can also be providedon the top of the fitting surface, making the top and bottom of themodules interchangeable.

FIGS. 11 a-b show a final attachment unit in accordance with oneembodiment of the invention. The attachment unit is used to fix or matethe bottom part of the last module of a series of modules. For example,the end module of a wall or the last of the middle modules to beassembled to form a wall. This is because fixing rods are not able to beused to attach these modules. The final attachment unit, in oneembodiment, comprises a final support bracket 854. The support bracket,for example, comprises substantially an L-shaped bracket with back andfoot portions 857 a-b. The back portion is attached to the bottom of afitting surface of the module. A plurality of openings 856 are providedon the back portion to facilitate attaching the support bracket to themodule. In one embodiment, the back portion comprises four verticalslotted openings corresponding to the four holes on the bottom of thefitting surface. The slotted openings allow for leveling adjustments tobe made due to, for example, variations in the base. Providing the backportion with other number or types of openings is also useful.

First wall fittings 870 ₁ for attaching the support bracket areinstalled into holes in the fitting surface. In one embodiment, thefirst wall fittings are inserted into first and last holes of the set ofplurality of holes in the lower portion of the module. For example, thefirst and fourth holes of the set of plurality of holes are fitted withwall fittings. As shown, a second wall fitting 870 ₂ is also fitted intoone of the holes between the first and last holes of the set ofplurality of holes, for example, either the second or third hole.However, since the fitting rod is not used, the use of the second wallfitting could be avoided. A second wall fitting (not shown) is alsoprovided for one of the holes in the top portion of the module. Firstbolts 873 are mated to the first wall fittings through the first andfourth vertical slotted openings to attach the support bracket to thefitting surface of the module. The foot portion extends from the bottomof the back portion to form a hook or latching surface. The distance Dbetween the latching surface and back should allow the fitting surfaceto fit and be held in place. Preferably, D provides a snug fit for thefitting surface. For example, D is equal to the thickness of the fittingsurface.

FIG. 12 a shows a final middle module being assembled in a wall. Asshown, the wall includes first and second portions 829 a-b. The portionsinclude modules 830 ₁ and 830 ₂ such as middle modules extending from,for example, corner modules, T-modules or a combination thereof Thefinal middle module 830 ₃ is inserted into the opening 827 between thetwo wall portions from the top, with the fitting surfaces mating. Forexample, the male fitting surface 822 of the final module is mated tothe female fitting surface of the first wall portion and the femalefitting surface 812 of the final middle module is mated to the malefitting surface of the second wall portion. As the final middle portionslides into position, final attachment units 854 hold it in place. Toaccommodate the final attachment unit, recesses are provided in thefitting surfaces of the middle and end modules. Bolts 872 are mated torespective wall fittings 871 ₂ in the top part of the fitting surfacesof the modules adjacent to the final module 830 ₃, as shown in FIG. 12b. End modules can be attached to an adjacent module in a similar mannerusing a final attachment unit at the bottom and bolts and fittings forthe top.

FIGS. 13 a-b illustrate a pillar module 332 in accordance with oneembodiment of the invention. As shown, the pillar module is attached toa module, for example, a middle module 330, on a wall portion 329. Toattach the pillar module, pillar attachment units are used. In oneembodiment, four pillar attachment units are used, two for the upperportion and two for the lower portion of the module. A pillar attachmentunit comprises a pillar support bracket 364. The pillar support bracketincludes a flat base portion 367 a and a stepped head portion 367 b.Holes 348 are provided on the base portion. As shown, first and secondholes are provided near the ends of the base portion. Providing otherhole configurations is also useful.

In one embodiment, pillar attachment units are mounted onto a wallmodule to create a male-type mating surface for the pillar module. Thepillar module is provided with slots 369 corresponding to the pillarattachment units, creating a female-type mating surface. Otherconfiguration of mating surfaces, such as providing the pillar modulewith a male-type mating surface while the wall module is provided with afemale-type mating surface or a combination thereof (e.g., each moduleis provided with both male-type and female-type mating surfaces), arealso useful.

To mount a pillar attachment unit, wall fittings 371 are installed intoholes provided onto the male-type mating surface. The holes, forexample, can be provided by drilling the male-type mating surface. Bolts372 are inserted through the holes of the base and mated to the wallfittings to securely mount the support bracket onto the mating surface.As shown, the pillar attachment unit is mated to the wall module withthe head portion facing upwards. Mounting the pillar attachment unitwith the head portion facing downwards (e.g., pillar module havingmale-type mating surface) is also useful.

The female and male mating surfaces are mated, attaching the pillarmodule to the wall module, as shown in FIG. 13 b. In one embodiment,pillar module comprises a height which is less than the height of thewall module. This is to accommodate the difference between the step andthe flooring. The pillar module, for example, is a load bearing modulewhich aids in the construction of multiple stories or to act as ananchor point for walls. As such, pillar modules can be provided whereneeded in the building structure.

FIGS. 14 a-d show a column assembly 439 in accordance with oneembodiment of the invention. The column assembly provides load bearingfunction and aids in general construction of the building structure,such as roof and additional floors. Column module assemblies can beprovided within the building structure as needed.

Referring to FIG. 14 a, the column assembly comprises a column support435 and first and second column modules 433 and 434. The column supportcan be formed from steel and is capable of supporting the desired load.For example, the column support comprises galvanized steel. The columnsupport, as shown, comprises first and second sub-columns 437 formed ona base plate 436. The sub-columns fit within the cavities 418 a-b of oneof the pillar modules. In one embodiment, the sub-columns are 50 mm×50mm×4 mm square hollow sections with 5 mm base plate. Providing columnsupport with other number of sub-columns is also useful, for example,depending on the size or number of cavities in the module. The base ofthe column support is mounted onto the base of the building structurewith, for example, base bolts through holes 438. In one embodiment, theholes are arranged such that two are located near the edge on one sideof the base and another two are located near the middle on an opposingside of the base. Other arrangements of holes or other techniques formounting the column support to the base are also useful.

One of the pillar modules is provided with the male-type mating surface464 which include pillar attachment units while the other comprises afemale-type mating surface 466 with slotted openings, as described in,for example, FIGS. 13 a-b. In one embodiment, the column support isinserted in the cavities of the male-type pillar module. Once the columnis within the cavities of the male-type pillar module, wall fittings 471are installed in holes in the module and the column support, as shown inFIG. 14 c. Bolts are inserted through holes in the support bracket andtightened, securing the module to the column support. The pillarattachment units are formed from, for example, 3 mm thick galvanizedsteel. Other materials or thicknesses are also useful. To accommodatethe base of the column support, recesses 418 are formed in the bottom ofthe pillar module 433, as shown in FIG. 14 d. The female-type pillarmodule is then mated to the male-type module, completing the columnassembly, as illustrated by FIG. 14 b.

FIGS. 15 a-c show a window frame 582 of a building system in accordancewith one embodiment of the invention. The window frame, in oneembodiment, comprises a plurality of capping layers 583. Various typesof materials can be used to form the capping layers. For example, steel,tin, wood, plastic or polymer can be used. Other types of materials arealso useful. The capping layer provides a surface which is mated to themodules' fitting surfaces or end surfaces. To form the window frame, thecapping layers can joined together. As shown, the window frame comprisesa rectangular shape with a height H, width W and thickness T formed byjoining four straight capping layers. The capping layers could be joinedusing mitre joints. Other window frame shapes or techniques for joiningthe capping layers are also useful. For example, the window frame can beformed from a single molded piece of material.

In one embodiment, W is selected to be a multiple of the smallest sizeunit of the modules, for example, half size (1 cavity). The width W canalso be of other dimensions. For example, W can be a multiple of fullsize modules or other dimensions.

In one embodiment, the capping layer comprises a U-shaped cross section.The top surface 584 of the capping layer includes a mounting surface 541a with a beveled edge 541 b. A window 549 is mounted onto the mountingsurface. To fix the window to the frame, window mounts 543 can be used.In one embodiment, window mounts are attached to the frame by, forexample, fasteners such as rivets or screws. The window can be fixed tothe mounts by rivets. Other techniques for mounting the window to theframe are also useful. In one embodiment, the window frame is arrangedsuch that the beveled edge faces outward. A bottom surface 547 is matedto the modules. For example, a bottom surface of the capping layer ismated to a middle module 529 as shown in FIG. 15 c. By providing aU-shaped cross-section, the capping layer can be fit to secure themodules. The frame can be attached to the modules by adhesive. Othertechniques for mounting the frame to the modules are also useful.

A wall 529 having an opening 525 is provided. The opening, for example,is formed by cutting modules in portion 528 to a length equal to theheight of the bottom of the window. The width of portion 528 correspondsto the width of the window frame. Illustratively, the width of portion528 is equal to the width of X full size modules, where X is a wholenumber. Other values of X are also useful, including non-whole numbers.

FIGS. 16 a-b show a door frame 661 for the building system in accordancewith one embodiment of the invention. The door frame, in one embodiment,comprises a plurality of frame rails 663. In one embodiment, the framerails are formed from steel. Other types of materials are also useful.For example, tin, wood, plastic or polymer can also be used. Typically,the door frame comprises a rectangular shape with an open side, having aheight H, width W and thickness T formed by joining three straight framerails layers. The frame rails could be joined using mitre joints.Joining can be achieved by, for example, welding or adhesives.Alternatively, the door frame can be formed from a single molded pieceof material. Other door frame shapes or techniques for joining the framerails are also useful.

In one embodiment, W is selected to be a multiple of the smallest sizeunit of the modules, for example, half size (1 cavity). The width W canalso be of other dimensions. For example, W can be a multiple of fullsize modules or other dimensions, including non-multiples of smallestsize unit.

In one embodiment, the frame rails comprise a U-shaped cross section.The U-shaped cross section provides a surface 662, as indicated bydotted lines, which is mated to the modules fitting surfaces or endsurfaces. A recess 665 is provided in the fitting surface. By providinga U-shaped cross-section, the frame rails can be fit to secure themodules.

FIGS. 17 a-b show different views of a door frame assembly in accordancewith one embodiment of the invention. As shown, first and secondportions 729 a-b of a wall with an opening 760 therebetween in which adoor frame 661 is to be disposed. The width of the opening correspondsto the width of the door frame. The wall sections are formed by, forexample, a plurality of middle sections coupled to corner or T-modules.Other wall configurations are also useful. The door frame is installedby sliding it from the top through the edge of the wall sections. Doorfitting bracket assemblies 773 are provided on the fitting surfaces ofthe last middle modules 730 of the wall sections adjacent to theopening. In one embodiment, each fitting surface is provided with threedoor fitting brackets. Other door fitting bracket configurations andnumber are also useful.

A door fitting bracket assembly comprises a door bracket. The doorbracket comprises a central portion 776 with an opening. One opposingsides of the central portion are winged portions 775. A wall fitting 771is installed into the fitting surface. To mount the door bracket to themodule fitting surface, a bolt 772 is inserted through the opening inthe central portion and mated to the wall fitting. In one embodiment,the profile of the bracket forms a male profile which is compatible tothe female profile of the frame rail to securely hold the door frame inposition when installed into the wall.

FIGS. 18-19 show plumbing outlet in accordance with one embodiment ofthe invention. Referring to FIG. 18, a wall 829 is shown. The wall isformed by, for example, a plurality of modules. Piping for plumbing runsthrough the modules. To access the piping for plumbing outlets, plumbingplugs 695 are provided. Plumbing plugs, for example, comprises PVCplugs. Other types of plugs are also useful. The plugs are installedinto the module to provide access to the pipes.

Referring to FIG. 19, the piping 694 for plumbing are preferably runthrough the cavities 918 of the modules 930. Plugs 695 are installedinto the module, providing access to the pipes. Preferably, the plugsinclude a tapered profile to aid in the tiling process. A plumbingoutlet 697, such as a tap fitting, is mounted on the module through theplug and mated to the pipes. In a preferred embodiment, the modules areformed from water resistant material, such as a polymer composite. Othertype s of water resistant materials are also useful. As such, there areno restrictions to where wet areas can be installed.

FIGS. 20-21 show a garage door assembly 256 in accordance with oneembodiment of the invention. Referring to FIG. 20, the garage doorassembly is installed into a wall having first and second portions 229a-b with an opening 260 therebetween. As shown, the wall portionscomprise a series of connected full size middle modules. The last moduleon the wall portions adjacent to the opening are cut to the height ofabout the top of the garage door. Other configurations of the wallportions are also useful. The opening comprises a width W correspondingto the width of the garage door. Preferably, W is selected to be amultiple of the smallest size unit of the modules, for example, halfsize (1 cavity). The width W can also be of other dimensions. Forexample, W can be a multiple of full size modules or other dimensions,including non-multiples of smallest size unit.

The garage door assembly, in one embodiment, comprises first and secondside brackets 257 a attached to ends of a u-channel rail 257 b. The sidebrackets are attached to mating surfaces of fitting surfaces ofpenultimate modules exposed by cutting of the end modules adjacent tothe opening. In one embodiment, the side brackets include a hooked topportion for hanging over the top of the fitting surface of a module. Toaccommodate the hooked top portion, the top of the modules can berecessed. The garage door assembly is formed, for example, from 4 mmthick galvanized steel. Bolts are inserted through holes in the bracketsand mated with wall fittings on the fitting surface to securely attachthe garage assembly to the wall. Middle modules cut to appropriate sizeare disposed on the u-channel railing, forming a wall portion 221 on thetop of the garage door. Other arrangements of installing the garage doorassembly are also useful. The fitting surfaces of the end modules belowthe garage door assembly are fitted with capping layers 583, forming agarage door opening having a width W and height H corresponding to thesize of the garage door.

Referring to FIG. 21, the garage door assembly includes side brackets257 a attached to the u-channel rail 257 b. In one embodiment, hooks 258are provided on the surface of the u-channel railing. The hooks are, forexample, equally spaced apart. Preferably, the hooks are located on therailing corresponding to the cavity of a module. In one embodiment, thehooks are J-shaped hooks as shown in FIG. 21. Other types and shapes ofhooks are also useful.

FIGS. 22 a-b show a roof plate assembly in accordance with oneembodiment of the invention. As shown, a roof plate 250 is provided overthe top of the garage. The roof plate is securely attached to the top ofthe modules. The roof plate serves as a base to which a roof frame isattached. In one embodiment, the roof plate is attached to the garageassembly 256 by roof plate fasteners 251. The roof plate fasteners, forexample, couple the plate to the hooks on the u-channel rail 257 b.

FIGS. 23 a-b show a roof plate assembly in accordance with oneembodiment of the invention in greater detail. As shown, the roof plateis attached to the garage door assembly 256 with roof plate fasteners251. In one embodiment, the roof plate fastener comprises a threadedhook 252. The threaded hook, for example, comprises 6 mm diametergalvanized steel with M6 thread on one end. The hook 252 is mated to thehook 258 on the u-channel railing, with the threaded portion passingthrough holes in the roof plate and secured by a washer and bolt 253.

FIGS. 24 a-c show a roof plate assembly in accordance with anotherembodiment of the invention. As shown, the roof plate is attached to awall 239 of the building structure. The roof plate is attached, in oneembodiment, to the fixing rods 270 connecting modules of the wall with aroof plate fastener 251. In one embodiment, the roof plate fastenercomprises a threaded hook 252, as previously described. The hook ismated to the fixing rod, with the threaded portion passing through holesin the roof plate and secured by a washer and bolt 253. In oneembodiment, modules to which the treaded hook is attached are anchoredto the base by base bolts. Preferably, the base bolts comprise ChemSet™base bolts. The use of the roof plate enhances stability, for example,enabling the building structure to withstand cyclone type environment.In another embodiment, the roof plate is directly coupled to the base.For example, a rod with threads on both ends is used. One end of the rodis coupled to a base bolt; such as a ChemSet™ base bolt. The head of thebase bolt includes a threaded opening for accommodating the rod. Theother end of the rod is coupled to the roof plate.

FIG. 25 shows a process for assembling a building in accordance with oneembodiment of the invention. The assembly process commences by formingthe base or foundation at step 910. The base, for example serves as afoundation for the modules to attach. The base, for example, comprisesconcrete. Conventional processes can be employed to form the base. Forexample, the footing on which the modules are attached are formed.Thereafter, the slab is formed. Other types of foundations are alsouseful. For example, the house can include a basement. In such case, thebasement foundation and structure is formed followed by the footing. Theflooring can then be formed with appropriate structural support formed.

At step 920, the external walls are formed. In one embodiment, thecorners of the external walls are first installed. For example, thecorner modules are attached to the footing using support brackets. Afterthe corner modules are installed, the walls are formed. The walls can beformed by installing and attaching middle modules or T-modules asappropriate. The modules are installed from the corner modules towardthe middle of the wall. Windows, doors, and pillars are installed asdesigned. Internal walls are formed at step 930. Like external walls,corner modules are first installed followed by intermediate modules,such as middle or T-modules. Doors and pillars are installed asdesigned.

After the formation of the internal walls, services (e.g., electricaland plumbing services) are installed at step 940. If additional floorsare included in the building structure, the process returns to step 910to form the footing and flooring for the next floor. Stairways, forexample, interconnecting the floors can be formed. Once all floors arecompleted, the process continues to form roof structure at stop 960.External walls can be rendered. For example, textured paints can beused. Other types of rendering can also be useful. Internal portions ofthe building structure are also finished, completing the buildingstructure. For example, gypsum boards can be installed and painted. Auseful type of wall finish comprises an acrylic textured finish known asDulux™.

FIG. 26 shows a process for forming modules in accordance with oneembodiment of the invention. An extrusion machine can be provided forthe different types of modules, for example, to have the desired form,including size and fitting surfaces. Alternatively, the different outputmolds can be provided to form different types of modules. Raw materialsare prepared at step 904 for extrusion. Additional preparation stepsinclude storage, buffering and feeding at step 908, batching andweighing at step 914 and mixing at step 918. After the raw material isprepared, a pre-extrusion is performed at step 924 followed by extrusionat step 928. The extruded material is pre-cut to the desired size,forming intermediate modules at step 934. The pre-cut modules arestacked and pre-cured at steps 938 and 944. The pre-cut modules arede-stacked and processed at step 948. For example, the pre-cut modulesare cut to the final length L at step 954, holes drilled at step 958 andrecess formed by routing at step 964. The prepared modules are stackedand cured for shipping at step 968.

The invention may be embodied in other specific forms without departingfrom the spirit or essential characteristics thereof. The foregoingembodiments, therefore, are to be considered in all respectsillustrative rather than limiting the invention described herein. Scopeof the invention is thus indicated by the appended claims, rather thanby the foregoing description, and all changes that come within themeaning and range of equivalency of the claims are intended to beembraced therein

1. A building system comprising: a plurality of different types ofmodules for forming external and internal walls of a building structure,wherein adjacent modules are interlocked by first and second fittingsurfaces of respective adjacent modules; and a fastening system forattaching first and second adjacent modules, the fastening systemcomprises a fixing rod and wall fitting unit, wherein one of the fittingsurfaces of the first adjacent module is fitted with the wall fittingunit and the fixing rod is inserted through the second adjacent module.2. The building system of claim 1 wherein the different types of modulescomprises: a corner module having first and second fitting surfaces formating with adjacent modules to form a bend in the building structure;and intermediate modules for interconnecting a plurality of cornerstructures to form external walls of the building structure.
 3. Thebuilding system of claim 2 wherein the intermediate modules comprise atleast middle modules having first and second fitting surface, the firstfitting surface comprises a male fitting surface and the second fittingsurface comprises a female fitting surface, the male and female surfacesof adjacent modules are interlocked.
 4. The building system of claim 3wherein intermediate modules further comprise T-modules which includefirst, second and third fitting surfaces for forming intersecting wallsin the building structure.
 5. The building system of claim 4 whereinfitting surfaces of the T-modules are interconnected with fittingsurfaces of middle modules to form intersection walls of the buildingstructure.
 6. The building system of claim 1 wherein the modulescomprises a length equal to a height of a wall.
 7. The building systemof claim 6 wherein the modules include at least one cavity through thelength thereof.
 8. The building system of claim 7 wherein the cavityfacilitates installation of services including plumbing and electricalservices.
 9. The building system of claim 1 wherein modules comprises ageopolymer composite.
 10. The building system of claim 9 wherein thegeopolymer composite comprises cement, fly ash, paper fiber and water.11. The building system of claim 10 wherein the geopolymer compositefurther comprises calcium carbonate, chemical methyl cellulose andrecycled dust.
 12. The building system of claim 1 wherein the modulescomprises an extruded geopolymer composite.
 13. The building system ofclaim 1 wherein fitting surfaces include a plurality of top holes and aplurality of bottom holes to facilitate attaching adjacent modules withthe fastening system, wherein first and second adjacent modules areattached together with a first of top and bottom holes and second andthird adjacent modules are attached together with a second of top andbottom holes.
 14. A method of assembling a building system comprising:providing a building structure base; mounting corner modules to thebuilding structure base at corners of the building structure base;mating interconnecting types of building modules sequentially from thecorner modules, wherein adjacent interconnecting types of buildingmodules are mated by male and female fitting surfaces; and attachingadjacent interconnecting types of building modules with a fasteningsystem, the fastening system comprises a wall fitting unit mounted onthe fitting surface of one of the modules and inserting a fixing rodthrough the other of the adjacent module and mating with the wallfitting unit.
 15. A method of forming a module of a building systemcomprising: preparing a geopolymer mixture of the module; inputting thegeopolymer mixture into an extrusion system; and extruding a module froma mold, wherein the module comprises at least a first fitting surfacefor mating with a module with a second fitting surface, wherein thefirst fitting surface comprises one of a male or female surface and thesecond fitting surface comprises other of a male or female surface. 16.The method of claim 15 wherein the geopolymer mixture comprises cement,fly ash, paper fiber and water.
 17. The method of claim 16 wherein thegeopolymer mixture further comprises calcium carbonate, chemical methylcellulose and recycled dust.